FineAdjust Applicator
Doc. No: TM-638004900
Release Date: 09-04-03
UNCONTROLLED COPY
Page 43 of 50
Revision: G
Revision Date: 01-15-13
A.5 Pull Force Testing
A.5.1
Pull Force Procedure
Wire connectors and soldering lugs for use with copper conductors. (Per UL486A November 15, 2003) UL Section 12
Pullout Test.
12.1 The connectors subjected to the static heating test or secureness test shall be subjected to a direct pull of the value
specified for one minute. Only those connectors that have been subjected to the secureness test are to be subjected
to the pullout test. The connector is acceptable if it does not become separated from the conductor or conductors after
completion of the test.
12.2 For an insulated connector in which the insulation is assembled to the connector during installation, the test should be
conducted with the insulation in place if it is always supplied with the connector by the manufacturer. Otherwise, the
test should be conducted without the insulation assembled to the connector. Breaking or tearing of the insulation of an
insulated connector is acceptable in the pullout test. The pull is to be exerted by means of a tension testing machine
or equivalent, so that there will be no sudden application of force or jerking during the test.
The following is the procedure Molex uses for the qualification of pull force:
1.
Cut wire length approximately 150mm (6.0”) long.
2.
Strip one end to 13mm (.50”), or long enough so no wire insulation is under the insulation grip.
3.
Terminate the appropriate terminal to the wire to the nominal crimp height.
4.
Visually inspect the termination for bell mouth, wire brush, and cut strands.
5.
Set pull tester to 25.4mm (1.0”) per minute. For most applications, a higher rate will not have a significant impact on the
data. Verify higher pull rates with data taken at 25.4mm (1.0”) per minute.
6.
Knot the non-terminated end of the wire.
7.
Regardless of pull tester type, both wire and terminated end must be securely clamped. (Note: When clamping the
terminated end, do not clamp the conductor crimp.)
8.
Activate pull test.
9.
Record a minimum of 25 readings of maximum pull force. After the application has been qualified, a minimum of 5 pull
force measurements should be done to confirm each setup.
10.
Compare lowest reading to minimum pull force specification.
A.5.2 Pull Test Problems
A.5.2.1 Wire breaks before conductor grip. Pull force low
Material Evaluation
Cause:
Wire material properties, and/or coatings.
Solution:
Test non-terminated wire for breaking strength. Change wire, if
necessary.
Stripping Evaluation
Cause:
Cut or nicked strands from stripping operation.
1) Wire being manually stripped.
2) Poor automatic stripping cutoff.
3) Worn strip tooling.
Solution:
1) Switch to semiautomatic or automatic wire stripping machine.
2) Correct stripping machine setup.
A.5.2.2 Wire pulls out of conductor grip, crimp height good
Material Evaluation
Cause:
1) Terminal material thickness too small.
Test Values For Pullout Test UL486A
Conductor Size
Pullout Force
AWG
mm
2
N
LBF
30
0.05
6.7
1.5
28
0.08
8.9
2
26
0.13
13.4
3
24
0.20
22.3
5
22
0.324
35.6
8
20
0.519
57.9
13
18
0.823
89.0
20
16
1.31
133.5
30
14
2.08
222.6
50
12
3.31
311.5
70
10
5.261
356.0
80
9
8.367
400.5
90
